Z750RS (Z2) Main harness replacement and more

DSC08289
First, let’s strip it down.

DSC08292
Since we’re not reusing switches and such, it’s a bit easier.

DSC08300
There are a lot of spots like this throughout. Electricity can easily cause a bike to catch fire, so I think it’s best not to work on it carelessly.

DSC08302
The burrs are pretty bad. You can really see why the instructions say to remove them.

DSC08304
The back is tight, so I’ll offset it about 10 mm forward. It’s too tight and dangerous.

DSC_1892
I’ll skip some images. Now I’ll secure the catch tank.

DSC_1904
Rear brake tank hose conversion adapter

DSC_1906
I ground down the rear brake tank boss and welded it.

DSC_1883
I welded and extended the breather.

DSC_1920
I fabricated a starter relay bracket.

DSC_1896
I bent and welded pipe to lay out the breather.

DSC08306
DSC08308
I changed how the rear brake switch is mounted.

DSC_1873
I won’t mount the relay components in their original location. This is to account for future risks from bending the wiring nearly 90 degrees.

DSC_1876
I ran the ground into the turn signal. Shared-bolt grounds aren’t ideal.

DSC_1875
If there’s room in the passageway, it’s always a spot I want to protect. I used screen molding (with metal). DSC08295
Long protruding bolts can damage the wiring, so I’ll cut them short with a guillotine.

It’s tedious work that takes time.

  • Copied the URL !